U.S. patent number 10,172,281 [Application Number 15/541,560] was granted by the patent office on 2019-01-08 for cutting deck flow control assembly.
This patent grant is currently assigned to HUSQVARNA AB. The grantee listed for this patent is HUSQVARNA AB. Invention is credited to David Briney, James R. Poole.
United States Patent |
10,172,281 |
Poole , et al. |
January 8, 2019 |
Cutting deck flow control assembly
Abstract
A cutting deck for housing first and second cutting blades
rotatable inside a cutting chamber is provided. The cutting deck
includes a weldment including a top plate and side plates. The top
plate includes first and second shaft reception orifices, and a
flow control assembly extending away from the top plate to define
an airflow channel between the flow control assembly and the side
plates. The flow control assembly includes a first directional
changing portion proximate to the first shaft reception orifice and
a second directional changing portion proximate to the second shaft
reception orifice. The first and second directional changing
portions are separated from each other by straight portions. The
first and second directional changing portions are passed over only
by respective ones of the first and second cutting blades, and both
the first and second cutting blades pass over the straight
portions.
Inventors: |
Poole; James R. (Salisbury,
NC), Briney; David (Charlotte, NC) |
Applicant: |
Name |
City |
State |
Country |
Type |
HUSQVARNA AB |
Huskvarna |
N/A |
SE |
|
|
Assignee: |
HUSQVARNA AB (Huskvarna,
SE)
|
Family
ID: |
56406147 |
Appl.
No.: |
15/541,560 |
Filed: |
January 12, 2015 |
PCT
Filed: |
January 12, 2015 |
PCT No.: |
PCT/US2015/010952 |
371(c)(1),(2),(4) Date: |
July 05, 2017 |
PCT
Pub. No.: |
WO2016/114746 |
PCT
Pub. Date: |
July 21, 2016 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20180020616 A1 |
Jan 25, 2018 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01D
34/667 (20130101) |
Current International
Class: |
A01D
34/66 (20060101) |
Field of
Search: |
;56/320.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1776858 |
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Apr 2007 |
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EP |
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839674 |
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Jun 1960 |
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GB |
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2525499 |
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Oct 2015 |
|
GB |
|
4791932 |
|
Oct 2011 |
|
JP |
|
2010140904 |
|
Dec 2010 |
|
WO |
|
2014152644 |
|
Sep 2014 |
|
WO |
|
2014152992 |
|
Sep 2014 |
|
WO |
|
2015016895 |
|
Feb 2015 |
|
WO |
|
Other References
International Search Report and Written Opinion in the
International patent application No. PCT/US2015/010952 dated May 6,
2015. cited by applicant .
International Preliminary Report on Patentability for International
Application No. PCT/US2015/010952 dated Jul. 18, 2017. cited by
applicant .
Toro, `Toro Blade Adapter`, accessed at
http://www.hy-capacity.com/index_php?page=Search&partid=55834,
accesses on Mar. 25, 2016, p. 2. cited by applicant.
|
Primary Examiner: Will; Thomas B
Assistant Examiner: Misa; Joan D
Attorney, Agent or Firm: McNair Law Firm, P.A.
Claims
The invention claimed is:
1. Outdoor power equipment comprising: a frame; an engine operably
coupled to the frame; and a cutting deck operably coupled to the
frame, the cutting deck housing at least a first cutting blade and
a second cutting blade, the first and second cutting blades being
rotatable responsive to operation of the engine, wherein the
cutting deck comprises a weldment comprising: a top plate and one
or more side plates defining a cutting chamber in which the first
and second cutting blades are rotatable responsive to operation of
the engine; and a flow control assembly disposed within the cutting
chamber and extending away from the top plate to define an airflow
channel between the flow control assembly and the one or more side
plates, wherein the flow control assembly comprises a first
directional changing portion disposed proximate to the first
cutting blade and a second directional changing portion disposed
proximate to the second cutting blade, the first and second
directional changing portions being separated from each other by
substantially straight portions of the flow control assembly,
wherein the first directional changing portion is passed over only
by the first cutting blade and the second directional changing
portion is passed over by only the second cutting blade, and both
the first and second cutting blades pass over the substantially
straight portions between the first and second directional changing
portions responsive to rotation of the first and second cutting
blades, wherein the flow control assembly comprises a first
sidewall portion and a second sidewall portion each of which extend
substantially perpendicularly away from the top plate, and wherein
the first and second sidewall portions extend across an interior
portion of the top plate to inhibit bending or sagging of the top
plate.
2. The outdoor power equipment of claim 1, wherein the first and
second sidewall portions each terminate at their respective ends at
corresponding bent portions, the bent portions of the first and
second sidewall portions meeting to form the first and second
directional portions.
3. The outdoor power equipment of claim 1, wherein the first and
second sidewall portions include stiffening ribs disposed in a
surface thereof.
4. The outdoor power equipment of claim 1, wherein the flow control
assembly forms a continuous enclosure concentrically disposed
within the cutting chamber relative to the one or more side
plates.
5. The outdoor power equipment of claim 1, wherein the one or more
side plates extend away from the top plate by a first distance and
the flow control assembly extends away from the top plate by a
second distance, and wherein the second distance is less than the
first distance by at least a blade profile depth amount.
6. The outdoor power equipment of claim 1, wherein the outdoor
power equipment comprises a riding lawn care device.
7. The outdoor power equipment of claim 1, wherein the outdoor
power equipment comprises a walk-behind lawn care device.
8. The outdoor power equipment of claim 1, wherein the cutting deck
comprises a side discharge opening provided in the one or more side
plates.
9. Outdoor power equipment comprising: a frame; an engine operably
coupled to the frame; and a cutting deck operably coupled to the
frame, the cutting deck housing at least a first cutting blade and
a second cutting blade, the first and second cutting blades being
rotatable responsive to operation of the engine, wherein the
cutting deck comprises a weldment comprising: a top plate and one
or more side plates defining a cutting chamber in which the first
and second cutting blades are rotatable responsive to operation of
the engine; and a flow control assembly disposed within the cutting
chamber and extending away from the top plate to define an airflow
channel between the flow control assembly and the one or more side
plates, wherein the flow control assembly comprises a first
directional changing portion disposed proximate to the first
cutting blade and a second directional changing portion disposed
proximate to the second cutting blade, the first and second
directional changing portions being separated from each other by
substantially straight portions of the flow control assembly,
wherein the first directional changing portion is passed over only
by the first cutting blade and the second directional changing
portion is passed over by only the second cutting blade, and both
the first and second cutting blades pass over the substantially
straight portions between the first and second directional changing
portions responsive to rotation of the first and second cutting
blades, and wherein the cutting deck further comprises a nose
baffle extending into the airflow channel away from a portion of
the one or more side plates.
10. Outdoor power equipment comprising: a frame; an engine operably
coupled to the frame; and a cutting deck operably coupled to the
frame, the cutting deck housing at least a first cutting blade and
a second cutting blade, the first and second cutting blades being
rotatable responsive to operation of the engine, wherein the
cutting deck comprises a weldment comprising: a top plate and one
or more side plates defining a cutting chamber in which the first
and second cutting blades are rotatable responsive to operation of
the engine; and a flow control assembly disposed within the cutting
chamber and extending away from the top plate to define an airflow
channel between the flow control assembly and the one or more side
plates, wherein the flow control assembly comprises a first
directional changing portion disposed proximate to the first
cutting blade and a second directional changing portion disposed
proximate to the second cutting blade, the first and second
directional changing portions being separated from each other by
substantially straight portions of the flow control assembly,
wherein the first directional changing portion is passed over only
by the first cutting blade and the second directional changing
portion is passed over by only the second cutting blade, and both
the first and second cutting blades pass over the substantially
straight portions between the first and second directional changing
portions responsive to rotation of the first and second cutting
blades, and wherein the cutting deck houses one or more additional
cutting blades, and wherein the flow control assembly comprises an
equal number of directional changing portions to a total number of
cutting blades.
11. The outdoor power equipment of claim 10, further comprising a
plurality of nose baffles extending into the airflow channel from
respective portions of the one or more side plates that are each
substantially equidistant between a respective pair of cutting
blades.
12. A cutting deck for outdoor power equipment, the outdoor power
equipment comprising at least a first cutting blade and a second
cutting blade rotatable inside a cutting chamber, the cutting deck
comprising a weldment comprising: a top plate and one or more side
plates defining the cutting chamber, the top plate comprising at
least a first shaft reception orifice through which a shaft of the
first cutting blade is extendable and a second shaft reception
orifice through which a shaft of the second cutting blade is
extendable; and a flow control assembly disposed within the cutting
chamber and extending away from the top plate to define an airflow
channel between the flow control assembly and the one or more side
plates, wherein the flow control assembly comprises a first
directional changing portion disposed proximate to the first shaft
reception orifice and a second directional changing portion
disposed proximate to the second shaft reception orifice, the first
and second directional changing portions being separated from each
other by substantially straight portions of the flow control
assembly, wherein the first directional changing portion is passed
over only by the first cutting blade and the second directional
changing portion is passed over by only the second cutting blade,
and both the first and second cutting blades pass over the
substantially straight portions between the first and second
directional changing portions responsive to rotation of the first
and second cutting blades, wherein the flow control assembly
comprises a first sidewall portion and a second sidewall portion
each of which extend substantially perpendicularly away from the
top plate, wherein the first and second sidewall portions extend
across an interior portion of the top plate to inhibit bending or
sagging of the top plate, wherein the first and second sidewall
portions each terminate at their respective ends at corresponding
bent portions, the bent portions of the first and second sidewall
portions meeting to form the first and second directional portions,
or wherein the first and second sidewall portions include
stiffening ribs disposed in a surface thereof.
13. The cutting deck of claim 12, wherein the flow control assembly
forms a continuous enclosure concentrically disposed within the
cutting chamber relative to the one or more side plates.
14. A cutting deck for outdoor power equipment, the outdoor power
equipment comprising at least a first cutting blade and a second
cutting blade rotatable inside a cutting chamber, the cutting deck
comprising a weldment comprising: a top plate and one or more side
plates defining the cutting chamber, the top plate comprising at
least a first shaft reception orifice through which a shaft of the
first cutting blade is extendable and a second shaft reception
orifice through which a shaft of the second cutting blade is
extendable; and a flow control assembly disposed within the cutting
chamber and extending away from the top plate to define an airflow
channel between the flow control assembly and the one or more side
plates, wherein the flow control assembly comprises a first
directional changing portion disposed proximate to the first shaft
reception orifice and a second directional changing portion
disposed proximate to the second shaft reception orifice, the first
and second directional changing portions being separated from each
other by substantially straight portions of the flow control
assembly, wherein the first directional changing portion is passed
over only by the first cutting blade and the second directional
changing portion is passed over by only the second cutting blade,
and both the first and second cutting blades pass over the
substantially straight portions between the first and second
directional changing portions responsive to rotation of the first
and second cutting blades, and wherein the cutting deck further
comprises a nose baffle extending into the airflow channel away
from a portion of the one or more side plates.
15. A cutting deck for outdoor power equipment, the outdoor power
equipment comprising at least a first cutting blade and a second
cutting blade rotatable inside a cutting chamber, the cutting deck
comprising a weldment comprising: a top plate and one or more side
plates defining the cutting chamber, the top plate comprising at
least a first shaft reception orifice through which a shaft of the
first cutting blade is extendable and a second shaft reception
orifice through which a shaft of the second cutting blade is
extendable; and a flow control assembly disposed within the cutting
chamber and extending away from the top plate to define an airflow
channel between the flow control assembly and the one or more side
plates, wherein the flow control assembly comprises a first
directional changing portion disposed proximate to the first shaft
reception orifice and a second directional changing portion
disposed proximate to the second shaft reception orifice, the first
and second directional changing portions being separated from each
other by substantially straight portions of the flow control
assembly, wherein the first directional changing portion is passed
over only by the first cutting blade and the second directional
changing portion is passed over by only the second cutting blade,
and both the first and second cutting blades pass over the
substantially straight portions between the first and second
directional changing portions responsive to rotation of the first
and second cutting blades, and wherein the cutting deck houses one
or more additional cutting blades, and wherein the flow control
assembly comprises an equal number of directional changing portions
to a total number of cutting blades.
16. The cutting deck of claim 15, further comprising a plurality of
nose baffles extending into the airflow channel from respective
portions of the one or more side plates that are each substantially
equidistant between a respective pair of shaft reception orifices.
Description
TECHNICAL FIELD
Example embodiments generally relate to outdoor power equipment
and, more particularly, some embodiments relate to a flow control
assembly for use inside a cutting deck of a lawn mower.
BACKGROUND
Lawn care tasks are commonly performed using various tools and/or
machines that are configured for the performance of corresponding
specific tasks. Certain tasks, like grass cutting, are typically
performed by lawn mowers. Lawn mowers themselves may have many
different configurations to support the needs and budgets of
consumers. Walk-behind lawn mowers are typically compact, have
comparatively small engines, and are relatively inexpensive.
Meanwhile, at the other end of the spectrum, riding lawn mowers,
such as lawn tractors, can be quite large. Riding lawn mowers can
sometimes also be configured with various functional accessories
(e.g., trailers, tillers, and/or the like) in addition to grass
cutting components. Riding lawn mowers provide the convenience of a
riding vehicle as well as a typically larger cutting deck as
compared to a walk-behind model.
By their very nature, lawn mowers of either type employ rotary
cutting blades that must be housed for safety reasons. However, the
housing of the mower blades within a cutting deck can also enhance
the general mowing experience when it is designed to implement
other useful functions like directing grass out of a discharge
chute or into a bagging attachment. To facilitate airflow control
within the housing, a number of strategies may be employed.
Cutting decks may generally be provided via stamped or fabricated
construction. A stamped cutting deck is typically lighter and is
formed using large molds and presses with thin gauge steel.
Meanwhile, fabricated cutting decks are built from heavier plate
steel and are formed via welding of various pieces together.
Although fabricated cutting decks may have a reputation for being
sturdier (by virtue of the heavier plate steel employed),
fabricated cutting decks also have a reputation for providing
poorer airflow than stamped cutting decks. Given the lighter
construction of the stamped cutting deck, the stamped cutting deck
is generally considered to be more flexible. Manufacturers are
therefore believed to have more control over the design processes
of stamped cutting decks to enable the manufacturers to better
streamline airflow within stamped cutting decks. In light of the
strong reputation that fabricated cutting decks already have for
sturdiness, it may be desirable to improve the flow characteristics
of such cutting decks to provide a cutting deck that is both sturdy
and also has streamlined airflow characteristics.
BRIEF SUMMARY OF SOME EXAMPLES
Some example embodiments may provide a cutting deck having a
fabricated construction, which further employs a "racetrack" baffle
to provide improved airflow for a multi-blade, fabricated cutting
deck.
In an example embodiment, outdoor power equipment is provided. The
equipment may include a frame, an engine operably coupled to the
frame, and a cutting deck operably coupled to the frame. The
cutting deck houses at least a first cutting blade and a second
cutting blade. The first and second cutting blades are rotatable
responsive to operation of the engine. The cutting deck includes a
weldment including a top plate and one or more side plates defining
a cutting chamber in which the first and second cutting blades are
rotatable responsive to operation of the engine, and a flow control
assembly disposed within the cutting chamber and extending away
from the top plate to define an airflow channel between the flow
control assembly and the one or more side plates. The flow control
assembly includes a first directional changing portion disposed
proximate to the first cutting blade and a second directional
changing portion disposed proximate to the second cutting blade.
The first and second directional changing portions are separated
from each other by substantially straight portions of the flow
control assembly. The first directional changing portion is passed
over only by the first cutting blade and the second directional
changing portion is passed over by only the second cutting blade,
and both the first and second cutting blades pass over the
substantially straight portions between the first and second
directional changing portions responsive to rotation of the first
and second cutting blades.
In another example embodiment, a cutting deck for outdoor power
equipment having at least a first cutting blade and a second
cutting blade rotatable inside a cutting chamber is provided. The
cutting deck includes a weldment including a top plate and one or
more side plates defining the cutting chamber. The top plate
includes at least a first shaft reception orifice through which a
shaft of the first cutting blade is extendable and a second shaft
reception orifice through which a shaft of the second cutting blade
is extendable, and a flow control assembly disposed within the
cutting chamber and extending away from the top plate to define an
airflow channel between the flow control assembly and the one or
more side plates. The flow control assembly includes a first
directional changing portion disposed proximate to the first shaft
reception orifice and a second directional changing portion
disposed proximate to the second shaft reception orifice. The first
and second directional changing portions are separated from each
other by substantially straight portions of the flow control
assembly. The first directional changing portion is passed over
only by the first cutting blade and the second directional changing
portion is passed over by only the second cutting blade, and both
the first and second cutting blades pass over the substantially
straight portions between the first and second directional changing
portions responsive to rotation of the first and second cutting
blades.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
Having thus described the invention in general terms, reference
will now be made to the accompanying drawings, which are not
necessarily drawn to scale, and wherein:
FIG. 1 illustrates a perspective view of the riding lawn care
vehicle according to an example embodiment;
FIG. 2A illustrates a top perspective view of a weldment for a
cutting deck of a riding lawn care vehicle in accordance with an
example embodiment;
FIG. 2B illustrates a bottom perspective view of the weldment in
accordance with an example embodiment;
FIG. 3 illustrates a bottom perspective view of the cutting deck
with other components attached in accordance with an example
embodiment;
FIG. 4A illustrates a top perspective view of a weldment for a
cutting deck having three blades in accordance with an example
embodiment; and
FIG. 4B illustrates a bottom perspective view of the weldment in
accordance with an example embodiment.
DETAILED DESCRIPTION
Some example embodiments now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all example embodiments are shown. Indeed, the
examples described and pictured herein should not be construed as
being limiting as to the scope, applicability, or configuration of
the present disclosure. Rather, these example embodiments are
provided so that this disclosure will satisfy applicable legal
requirements. Like reference numerals refer to like elements
throughout. Furthermore, as used herein, the term "or" is to be
interpreted as a logical operator that results in true whenever one
or more of its operands are true. Additionally, the term "lawn
care" is meant to relate to any yard maintenance activity and need
not specifically apply to activities directly tied to grass, turf
or sod care. As used herein, operable coupling should be understood
to relate to direct or indirect connection that, in either case,
enables functional interconnection of components that are operably
coupled to each other.
As indicated above, a fabricated cutting deck is often thought to
be less capable (due to the more rigid steel construction) of being
designed to foster streamlined airflow. However, some example
embodiments may provide an airflow control assembly that can be
employed even within a fabricated cutting deck to improve airflow
characteristics. In this regard, for example, some embodiments may
provide the cutting deck further with a baffle (e.g., shroud)
having a "racetrack" shape to extend around the downshafts of
multiple cutting blades. The baffle may create a flow channel that
enhances airflow within the cutting deck.
FIG. 1 illustrates an example lawn care device in the form of a
riding lawn care vehicle 10 having a bagging attachment 12.
However, it should be appreciated that example embodiments may be
employed on numerous other riding lawn care vehicles that may not
include a bagging attachment 12. The riding lawn care vehicle 10
may also include an operations panel 14 that may display
operational information regarding the riding lawn care vehicle 10
and host various controls, gauges, switches, displays, and/or the
like. As shown and described herein, the riding lawn care vehicle
10 may be a riding lawn mower (e.g., a lawn tractor, front-mount
riding lawn mower, riding lawn mower with a zero or near zero
degree radius of turn, cross mower, stand-on riding lawn mower,
and/or the like). However, other example embodiments may be
employed on other multi-blade lawn mowers, such as walk behind lawn
mowers with wide decks, stand on mowers, mowers with zero (or near
zero) turning radius, and/or the like.
The riding lawn care vehicle 10 may include a steering assembly 20
(e.g., including a steering wheel, handle bars, or other steering
apparatus) functionally connected to wheels of the riding lawn care
vehicle 10 to which steering inputs are provided (e.g., the front
and/or rear wheels in various different embodiments) to allow the
operator to steer the riding lawn care vehicle 10. In some
embodiments, the riding lawn care vehicle 10 may include a seat 30
that may be disposed at a center, rear, or front portion of the
riding lawn care vehicle 10. The operator may sit on the seat 30,
which may be disposed to the rear of the steering assembly 20 to
provide input for steering of the riding lawn care vehicle 10 via
the steering assembly 20.
The riding lawn care vehicle 10 may also include, or be configured
to support attachment of, a cutting deck 40 having more than one
cutting blade mounted therein. In some cases, a height of the at
least one cutting blade may be adjustable by an operator of the
riding lawn care vehicle 10. The cutting deck 40 may be a fixed or
removable attachment in various different embodiments. Moreover, a
location of the cutting deck 40 may vary in various alternative
embodiments. For example, in some cases, the cutting deck 40 may be
positioned in front of the front wheels 42, behind the rear wheels
44, or in between the front and rear wheels 42 and 44 (as shown in
FIG. 1) to enable the operator to cut grass using the at least one
cutting blade when the at least one cutting blade is rotated below
the cutting deck 40. In some embodiments, the cutting deck 40 may
be lifted or rotated relative to the lawn mower frame to permit
easier access to the underside of the lawn mower without requiring
removal of the cutting deck 40. The cutting deck 40 may have two,
three, or more cutting blades driven by two, three, or more
rotatable shafts. The shafts may be rotated by any number of
mechanisms. For example, in some embodiments, the shafts are
coupled to a motor via a system of belts and pulleys. In other
embodiments, the shafts may be coupled to the motor via a system of
universal joints, gears, and/or other shafts. In still other
embodiments, such as in an electric lawn mower, the shaft may
extend directly from an electric motor positioned over the cutting
deck. In any case, the shafts may extend downward through a top
portion of the cutting deck 40 in a manner described in greater
detail below.
In some embodiments, the front wheels 42 and/or the rear wheels 44
may have a shielding device positioned proximate thereto in order
to prevent material picked up in the wheels from being ejected
toward the operator. Fender 46 is an example of such a shielding
device. When operating to cut grass, the grass clippings may be
captured by a collection system (e.g., bagging attachment 12),
mulched, or expelled from the cutting deck 40 via either a side
discharge or a rear discharge.
The riding lawn care vehicle 10 may also include additional
control-related components such as one or more speed controllers,
brakes, cutting height adjusters, and/or the like. Some of the
controllers, such as the speed controllers and/or brakes, may be
provided in the form of foot pedals that may sit proximate to a
footrest 48 (which may include a portion on both sides of the
riding lawn care vehicle 10) to enable the operator to rest his or
her feet thereon while seated in the seat 20.
In the pictured example embodiment of FIG. 1, an engine 50 of the
riding lawn care vehicle 10 is disposed substantially forward of a
seated operator. However, in other example embodiments, the engine
50 could be in different positions such as below or behind the
operator. In some embodiments, the engine 50 may be operably
coupled to one or more of the wheels of the riding lawn care
vehicle 10 in order to provide drive power for the riding lawn care
vehicle 10. In some embodiments, the engine 50 may be capable of
powering two wheels, while in others, the engine 50 may power all
four wheels of the riding lawn care vehicle 10. Moreover, in some
cases, the engine 50 may manually or automatically shift between
powering either two wheels or all four wheels of the riding lawn
care vehicle 10. The engine 50 may be housed within a cover that
forms an engine compartment to protect engine 50 components and
improve the aesthetic appeal of the riding lawn care vehicle
10.
In an example embodiment, the engine compartment may be positioned
proximate to and/or mate with portions of a steering assembly
housing 60. The steering assembly housing 60 may house components
of the steering assembly 20 to protect such components and improve
the aesthetic appeal of the riding lawn care vehicle 10. In some
embodiments, a steering wheel 62 of the steering assembly 20 may
extend from the steering assembly housing 60 and a steering column
(not shown) may extend from the steering wheel 62 down through the
steering assembly housing 60 to components that translate inputs at
the steering wheel 62 to the wheels to which steering inputs are
provided.
In some embodiments, the engine 50 may also provide power to turn
the cutting blades disposed within the cutting deck 40. In this
regard, for example, the engine 50 may be used to turn a shaft upon
which each of the cutting blades may be fixed (e.g., via a belt and
pulley system and/or other mechanisms). The turning of the
shaft(s), at high speeds, may move the cutting blades through a
range of motion that creates air movement that tends to straighten
grass for cutting by the moving blade and then eject the cut grass
out of the cutting deck 40 (e.g., to the bagging attachment 12 or
to the back or side of the riding lawn care vehicle 10), unless the
blades and mower are configured for mulching.
In an example embodiment, the engine 50 may turn at least one shaft
that is coupled to corresponding ones of one or more cutting blades
within the cutting deck 40 via a PTO clutch. When the PTO clutch is
engaged, rotary power generated by the engine 50 may be coupled to
the one or more cutting blades to cause rotation thereof (e.g., for
cutting grass). When the PTO clutch is disengaged, rotary power
generated by the engine 50 may not be coupled to the one or more
cutting blades and thus the cutting blades may not rotate. In some
embodiments, engagement of the PTO clutch may be accomplished via
operation of a PTO switch 70 that may be disposed on or proximate
to the operations panel 14.
The operations panel 14, or some other portion of the steering
assembly housing 60, may also provide support for an ignition
interface 80 of an example embodiment. The ignition interface 80
may be used for starting the engine 50 and for controlling other
functions of the riding lawn care vehicle 10. In an example
embodiment, the ignition interface 80 may not require a key to
operate. Thus, the operator of the riding lawn care vehicle 10 may
be enabled to start and/or initiate one or more functional
capabilities of the riding lawn care vehicle 10 without the use of
a physical key.
The cutting deck 40 of an example embodiment may be a fabricated
cutting deck. As such, the cutting deck 40 may be formed from
relatively large gauge, or thicker steel, than a typical stamped
cutting deck. The cutting deck 40 may also therefore be a weldment
that is constructed of a plurality of portions that are welded
together to form the cutting deck 40. Some examples of structures
that may be employed to form the cutting deck 40 are described in
greater detail below in reference to FIGS. 2-4.
FIG. 2, which includes FIGS. 2A and 2B, illustrates a perspective
view of one example of a cutting deck weldment 100 that may form
the cutting deck 40 of some examples. FIG. 2A illustrates a top
perspective view of the weldment 100 and FIG. 2B illustrates a
bottom perspective view of the weldment 100. FIG. 3 illustrates a
bottom perspective view of the weldment 100 with various other
components operably coupled thereto also shown in their
corresponding locations according to one example embodiment.
The weldment 100 may include a top plate 110 having a plurality of
shaft reception orifices 112 formed therein. The number of shaft
reception orifices 112 may be equal to the number of blades (and
corresponding shafts) employed in the cutting deck 40. In this
example, a first shaft 120 and a second shaft 122 are provided with
a corresponding first blade 124 and second blade 126, respectively,
attached thereto. The first and second shafts 120 and 122 may be
extended through the shaft reception orifices 112 to provide
operable coupling between the first and second blades 124 and 126
and the engine 50 of the riding lawn care vehicle 10 via, for
example, a belt 128 or other coupling device.
The top plate 110 may be welded to one or more side plates 114 that
may extend substantially perpendicularly from peripheral edges of
the top plate 110 to define a cutting chamber 130. The top plate
110 and/or side plates 114 may also have brackets 116 formed on
external surfaces thereof to enable the weldment 100 to be operably
coupled to the riding lawn care vehicle 10. A gap may be formed at
a portion of the top plate 110 and/or side plates 114 to define a
discharge opening 140 that may be disposed to direct ejected grass
to one side or the other of the riding lawn care vehicle 10. As the
first and second blades 124 and 126 turn to cut grass in the
cutting chamber 130, a rotating air current may be generated in the
cutting chamber 130 to stand grass up prior to cutting. Each blade
tends to create its own rotating current extending circularly
around itself. In a single blade system, this rotating air current
also takes the cut grass efficiently toward the discharge opening
140, which is a side discharge in this example embodiment. However,
for a multiple blade system, a high pressure area can be created
between the blades, and pressure buildup between the blades can
lead to incoherent airflow in this region. The creation of
streamlined airflow in the cutting chamber 130 can enhance the
efficiency of ejection and inhibit buildup of grass and/or debris
sticking to inside walls of the cutting chamber 130.
As indicated above, the discharge opening 140 is a side discharge
for a multi-blade cutting deck. If the discharge opening 140 were
instead located centrally within the cutting deck 40 (e.g., in a
rear discharge configuration), the racetrack configuration may be
less helpful. In this regard, for example, the blades could each
push the grass to the centrally located discharge so that the total
distance traveled by the grass is less. However, for a longer
distance traveled by clippings cut further from the discharge
opening 140, the creation of a coherent flow to move grass
effectively over the longer distance to the discharge opening
becomes an even more desirable feature. Thus, a structure may be
provided to improve the airflow in the cutting chamber 130.
In an example embodiment, an airflow control assembly 150 may also
be provided within the cutting chamber 130 to improve streamlining
of the airflow. The airflow control assembly 150 may be provided to
extend downwardly from the top plate 110 proximate to the shaft
reception orifices 112 and therefore also proximate to the first
and second shafts 120 and 122. As can be appreciated from FIGS. 2
and 3, the airflow control assembly 150 may tend to inhibit airflow
from passing immediately around each of the blades and may actually
form a channel to facilitate coherent passage of airflow around the
airflow control assembly 150 on the way to the discharge opening
140. Arrows 151 and 153 show the airflow moving in a
counterclockwise direction (for the perspective shown) toward and
out of the discharge opening 140. This may facilitate forcing
pressure out of the middle region between the blades to create
coherent airflow in a consistent direction within the cutting deck
40.
In some cases, the airflow control assembly 150 may be formed from
a first sidewall portion 152 and a second sidewall portion 154 that
each form opposing halves of the airflow control assembly 150 and
which are welded to each other at longitudinal ends thereof. The
first and second sidewall portions 152 and 154 may also be welded
to the top plate 110. In an example embodiment, the first and
second sidewall portions 152 and 154 may each extend substantially
perpendicularly away from the top plate 110 into the cutting
chamber 130 to form an airflow channel 160 between the first and
second sidewall portions 152 and 154 and the side plates 114 of the
weldment 100. As such, in some cases, the first and second sidewall
portions 152 and 154 may be substantially parallel to the
corresponding portions of the side plates 114 that are closest
thereto, and may also be concentric with the side plates 114. The
first and second sidewall portions 152 and 154 may therefore form
an elongated annular structure that substantially matches the shape
of the side plates 114, but on a smaller scale. The shape of the
airflow channel 160 is therefore a "racetrack" shape that can
provide for streamlined airflow therein.
The first and second sidewall portions 152 and 154 may be
elongated, relatively thin metallic strips (e.g., 1/8 inch steel)
that are substantially straight except that each is bent proximate
to both respective ends thereof. The bends at end portions of each
of the first and second sidewall portions 152 and 154 may be formed
in the same direction. However, the bends at ends of the first
sidewall portion 152 may be formed in a direction opposite the
direction in which ends of the second sidewall portion 154 are
formed. Accordingly, when welded to the top plate 110, the end
portions of the first and second sidewall portions 152 and 154 may
bend toward each other and be welded or otherwise affixed to each
other to form the airflow control assembly 150 into a continuous
structure. The straight portions of each of the first and second
sidewall portions 152 and 154 may be parallel to each other.
It should be appreciated that in some cases, the airflow control
assembly 150 could alternatively be formed from a single elongated
metallic structure that is bent at its ends and at its middle in
order to form two straight portions and two bent portions (the ends
of the single metallic structure meeting each other at one of the
bent portions or one of the straight portions to define the
continuous structure). Thus, for example, the first and second
sidewall portions 152 and 154 could be parts of the same unitary
piece of metal. Alternatively, the airflow control assembly 150
could be formed from a number of smaller structures joined together
such that the first and second sidewall portions 152 could each be
assembled from smaller parts. However, in any case, the airflow
control assembly 150 may include substantially straight portions
extending between bent portions that are disposed proximate to
blade reception orifices. The bent portions may be provided to make
substantial directional changes for extension of sidewalls of the
airflow control assembly 150, and the straight portions (which
could actually have some slight curvature to them, but generally
maintain a consistent direction extending between bent portions)
may extend between the bent portions. Moreover, each straight
portion may have at least a portion thereof that is proximate to at
least two rotating blades, while each bent portion may only be
proximate to one (i.e., the closest) rotating blade.
In the context of the example of FIGS. 2 and 3, the first and
second blades 124 and 126 both pass over (from the perspective of a
viewer looking into the cutting chamber 130 from below) both of the
straight portions of both of the first and second sidewalls 152 and
154. However, the first blade 124 only passes over the bent portion
closest to the first blade 124 and does not pass over the bent
portion closest to the second blade 126. Meanwhile, the second
blade 126 only passes over the bent portion closest to the second
blade 126 and does not pass over the bent portion closest to the
first blade 124. It should be appreciated that the term "pass over"
describes the relative situation expressed in FIGS. 2 and 3 based
on the views provided, but the blades literally pass "under" the
first and second sidewalls 152 and 154. Thus, the term "pass over"
should be appreciated as being equally applicable to passing under
or otherwise proximate to the first and second sidewall portions
152 and 154 in other situations where different perspectives apply
as well.
Although not required, the bent portions may further include
stiffening ribs 180 provided to extend along a longitudinal
direction of the ends of the first and second sidewall portions 152
and 154. Such stiffening ribs 180 may not be provided in the
straight portions. Thus, the first blade 124 only passes over the
stiffening ribs 180 closest to the first blade 124 and does not
pass over the stiffening ribs 180 closest to the second blade 126.
Meanwhile, the second blade 126 only passes over the stiffening
ribs 180 closest to the second blade 126 and does not pass over the
stiffening ribs 180 closest to the first blade 124. In some cases,
the top plate 110 may also include stiffening ribs 182 provided
therein to prevent sagging or other bending of the top plate 110.
However, the first and second sidewall portions 152 and 154 may
also serve to support interior portions of the top plate 110 to
reinforce and strengthen the top plate 110 to prevent sagging or
bending thereof.
A height of the first and second sidewalls 152 and 154 may be
measured in a direction extending away from the top plate 110.
Likewise, a height of the side plates 114 may also be measured in
the direction extending away from the top plate 110. Generally
speaking, the height of the first and second sidewalls 152 and 154
may be less than the height of the side plates 114 by an amount
slightly greater than a maximum depth of the blades measured
between the farthest ends of the blade in a direction parallel to
the axis of rotation of the blades (e.g., a blade profile
depth).
In some embodiments, the weldment 100 may be further provided with
a nose baffle 190. The nose baffle 190, although not required, may
be provided at both or only a single portion of the region between
the blades extending inwardly from the side plates 114 toward the
airflow control assembly 150. In the example of FIGS. 2 and 3, the
nose baffle 190 may extend from a rearward and bottom portion of
the side plates 114 (the bottom portion of the side plates 114
appears on top in the upside down views of FIGS. 2B and 3). The
nose baffle 190 also has a substantially triangular or pyramidal
shape as it extends into the region between the blades to provide a
lower bound to the airflow channel 160 in this region. The nose
baffle 190 may prevent pressure buildup in this region and further
facilitate coherent airflow in the airflow channel 160.
FIG. 4, which includes FIGS. 4A and 4B, shows perspective views
from the top (FIG. 4A) and bottom (FIG. 4B) of a weldment 200 that
may be employed for an example structure with more than two blades
in accordance with an example embodiment. The weldment 200 may
include a top plate 210 having a plurality of shaft reception
orifices 212 formed therein. In this example, since three blades
would be employed, there are a corresponding three shaft reception
orifices 212.
The top plate 210 may be welded to one or more side plates 214 that
may extend substantially perpendicularly from peripheral edges of
the top plate 210 to define a cutting chamber 230. However, note
that this example includes two nose baffles 290 that, instead of
being added to the interior of the cutting chamber 230 by extending
inwardly from the side plates 214, are integrally formed in the
side plates 214 at a rear portion of the cutting deck 40. The top
plate 210 and/or side plates 214 may also have brackets 216 formed
on external surfaces thereof to enable the weldment 200 to be
operably coupled to the riding lawn care vehicle 10. A gap may be
formed at a portion of the top plate 210 and/or side plates 214 to
define a discharge opening 240. As the blades (not shown) turn to
cut grass in the cutting chamber 230, a rotating air current may be
generated in the cutting chamber 230 to stand grass up prior to
cutting. As mentioned above, an airflow control assembly 250 may be
provided within the cutting chamber 230 to improve streamlining of
the airflow.
The airflow control assembly 250, again in similar fashion to the
prior example, may be provided to extend downwardly from the top
plate 210 proximate to the shaft reception orifices 212 to enclose
each of the shaft reception orifices 212 in a region outlined by
the airflow control assembly 250. As can be appreciated from FIG.
4, the airflow control assembly 250 may tend to inhibit airflow
from passing immediately around each of the blades and may actually
form a channel (e.g., airflow channel 260) to facilitate coherent
passage of airflow around the outside of the airflow control
assembly 250 on the way to the discharge opening 240. This may
facilitate forcing pressure out of the middle regions formed
between each of the blades to create coherent airflow in a
consistent direction within the cutting deck 40.
The airflow control assembly 250 may be formed of one or more
sidewall portions 252, similar to the description provided above
for the example of FIGS. 2 and 3. Similar to that example, the
sidewall portions 252 could be provided in any of a number of
different ways (e.g., as one or a plurality of pieces). The
sidewall portions 252 may be welded to the top plate 210 and extend
substantially perpendicularly away from the top plate 210 into the
cutting chamber 230 to form the airflow channel 260 between the
sidewall portions 252 and the side plates 214 of the weldment 200.
As such, in this example also, the shape of the airflow channel 260
is generally that of a "racetrack" shape that can provide for
streamlined airflow therein.
The sidewall portions 252 in this example may also be elongated,
relatively thin metallic strips that are substantially straight
except that each is bent proximate to any necessary changes in
direction that occur due to the placement of corresponding shaft
reception orifices 212. Accordingly, in more general terms, the
airflow control assembly 250 of an example embodiment may be
considered to be formed from an equal number of directional
changing portions 256 to the number of blades employed (and the
number of shaft reception orifices 212), and a set of two opposing
substantially straight portions 258 extending in between opposing
ends of each of the directional changing portions 256 as shown in
FIG. 4. Furthermore, for these multiple-blade embodiments, each
directional changing portion 256 is passed over by, proximate to,
and/or in the blade shadow zone of only a single (i.e., the
closest) rotating blade. However, each of the two substantially
straight portions 258 extending away from the directional changing
portions 256 is passed over by, proximate to, and/or in the blade
shadow zone of two rotating blades. This ensures that a "racetrack"
shape and corresponding streamlined airflow through the resulting
airflow channel (e.g., airflow channel 260) can be achieved for any
number of blades provided in the cutting deck 40.
As discussed above, the directional changing portions 256 (or bent
portions) may further include stiffening ribs 280 provided to
extend along a longitudinal direction of the sidewall portions 252.
In some cases, the top plate 210 may also include stiffening ribs
282 provided therein to prevent sagging or other bending of the top
plate 210. However, the sidewall portions 252 may also serve to
support interior portions of the top plate 210 to reinforce and
strengthen the top plate 210 to prevent sagging or bending
thereof.
Accordingly, a cutting deck and corresponding outdoor power
equipment having such a cutting deck are provided in accordance
with an example embodiment. The outdoor power equipment may include
at least a first cutting blade and a second cutting blade rotatable
inside a cutting chamber is provided. The cutting deck includes a
weldment including a top plate and one or more side plates defining
the cutting chamber. The top plate includes at least a first shaft
reception orifice through which a shaft of the first cutting blade
is extendable and a second shaft reception orifice through which a
shaft of the second cutting blade is extendable, and a flow control
assembly disposed within the cutting chamber and extending away
from the top plate to define an airflow channel between the flow
control assembly and the one or more side plates. The flow control
assembly includes a first directional changing portion disposed
proximate to the first shaft reception orifice and a second
directional changing portion disposed proximate to the second shaft
reception orifice. The first and second directional changing
portions are separated from each other by substantially straight
portions of the flow control assembly. The first directional
changing portion is passed over only by the first cutting blade and
the second directional changing portion is passed over by only the
second cutting blade, and both the first and second cutting blades
pass over the substantially straight portions between the first and
second directional changing portions responsive to rotation of the
first and second cutting blades.
In an example embodiment, various optional additions, modifications
and/or augmentations may be provided for the cutting deck described
above. In this regard, for example, (1) the flow control assembly
may include a first sidewall portion and a second sidewall portion
each of which extend substantially perpendicularly away from the
top plate. In an example embodiment, (2) the first and second
sidewall portions may extend across an interior portion of the top
plate to inhibit bending or sagging of the top plate. In such an
example, (3) the first and second sidewall portions may each
terminate at their respective ends at corresponding bent portions
and the bent portions of the first and second sidewall portions may
meet to form the first and second directional portions.
Additionally or alternatively, (4) the first and second sidewall
portions may include stiffening ribs disposed in a surface thereof.
In some embodiments, (5) the cutting deck may further include a
nose baffle extending into the airflow channel from a portion of
the one or more side plates substantially equidistant from the
first shaft reception orifice and the second shaft reception
orifice. In an example embodiment, (6) the cutting deck may house
one or more additional cutting blades, and the flow control
assembly may include an equal number of directional changing
portions to a total number of cutting blades. In such an example,
(7) the cutting deck may include a plurality of nose baffles
extending into the airflow channel from respective portions of the
one or more side plates that are each substantially equidistant
between a respective pair of shaft reception orifices.
In some cases, some or all of the examples described above may be
further augmented or modified in any desirable combination. For
example, any or all of (1) to (7) may be employed and the flow
control assembly may form a continuous enclosure concentrically
disposed within the cutting chamber relative to the one or more
side plates. Alternatively or additionally, any or all of (1) to
(7) may be employed and the one or more side plates may extend away
from the top plate by a first distance and the flow control
assembly extends away from the top plate by a second distance. In
such an example, the second distance may be less than the first
distance by at least a blade profile depth amount. Many
modifications and other embodiments of the inventions set forth
herein will come to mind to one skilled in the art to which these
inventions pertain having the benefit of the teachings presented in
the foregoing descriptions and the associated drawings. Therefore,
it is to be understood that the inventions are not to be limited to
the specific embodiments disclosed and that modifications and other
embodiments are intended to be included within the scope of the
appended claims. Moreover, although the foregoing descriptions and
the associated drawings describe exemplary embodiments in the
context of certain exemplary combinations of elements and/or
functions, it should be appreciated that different combinations of
elements and/or functions may be provided by alternative
embodiments without departing from the scope of the appended
claims. In this regard, for example, different combinations of
elements and/or functions than those explicitly described above are
also contemplated as may be set forth in some of the appended
claims. In cases where advantages, benefits or solutions to
problems are described herein, it should be appreciated that such
advantages, benefits and/or solutions may be applicable to some
example embodiments, but not necessarily all example embodiments.
Thus, any advantages, benefits or solutions described herein should
not be thought of as being critical, required or essential to all
embodiments or to that which is claimed herein. Although specific
terms are employed herein, they are used in a generic and
descriptive sense only and not for purposes of limitation.
* * * * *
References